Continuous embossing belt

ABSTRACT

An optically precise endless embossing belt for making retroreflection materials having projections with 90° corners is provided by the instant invention.

CROSS-REFERENCES TO RELATED APPLICATION

This is a continuation of application Ser. No. 06/627,285 filed Jul. 2,1984, now abandoned which is a division of application Ser. No.06/430,866 filed Sep. 20, 1982, which is now U.S. Pat. No. 4,478,769.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is directed to the field of continuous embossing ofsheeting or webs and more particularly to methods and apparatus ofproducing large scale, flexible, and generally cylindrical embossingtools to emboss continuous plastic webs or the like with a highlyaccurate pattern of cube-corners useful in the manufacture ofretroreflective sheeting.

2. Description of the Prior Art

Some presently employed techniques for the production of retroreflectivesheeting include the casting of cube corners on cylindrical drums,followed by an application of secondary material, whereby the cubecorner elements are adhered to a different back-up material. (e.g., U.S.Pat. No. 3,935,359).

Sequential embossing of cube corner type sheeting material has beensuggested by using a series of tooled plates and molds. The web ofmaterial is embossed on one stroke of the press and then indexed to thenext station for a further pressing operation (U.S. Pat. No. 4,244,683).This process, while operating on a continuous strip of material, is onlysequential in nature and has all of the economic and manufacturingdeficiencies inherent in such a process. Moreover, to be economicallyfeasible, the width of film or sheeting to be produced, such as 48",requires extensive mold handling capability not contemplated by theRowland '683 structure and process.

Small, rigid cylindrical rolls also are available for the generalcontinuous embossing of webs of sheet material but, because of the highdegree of optical accuracy required in reproducing cube corner elements,this technique has not been used to produce continuous sheeting.

Continuous belt type embossing tools also have been disclosed forembossing non-optically critical patterns in thermoplastic or othermaterials, such as shown in Bussey et. al., U.S. Pat. No. 3,966,383. Italso is well known in the cube-corner reflector art to use electroformedtools for producing mold elements. However, the relatively small areaencompassed by the typical reflective area permits the easy separationof the electroformed part from its "master" or from pins. To produce atool required to emboss large areas of sheet, it would be possible toassemble larger and longer groups of masters, but minute seams would befound at the junction lines. Those seams in a final tool could producestress risers, flash or fins, leaving the assembled tool with possiblefatigue areas. In accordance with the present invention, the pieces arereproduced by eliminating the "fin" or seam and then by producing acylindrical mother and electroforming internally of the tool mother. Aproblem then encountered is the removal of the cylindrical electroformedtool from the tool mother because of the very accurate but tightlyinterfitting male and female faces. The present invention disclosestechniques and apparatus for producing a cylindrical embossing a tool byelectroforms; and a method of separating the finished tool from thecylindrical tool mother.

SUMMARY OF THE INVENTION

The present invention overcomes the difficulties noted with respect toprior art embossing tools by providing methods and apparatus for makinglarge scale, flexible, generally cylindrical embossing tools forembossing highly accurate cube corner or other types of patternsrequiring extremely accurate precision formations continuously upon amoving web of plastic or other suitable material.

One or more highly accurate optical quality master elements is cut intosuitable substrates. Each master consists of a precision pattern which,in the specific disclosed embodiment, may take the form of tetrahedronsor the like formed when three series of parallel grooves are scribedinto the substrate along each of three axes, each axis being spaced fromthe other two by 120°. Each master element has a series of marginaledges of a geometric figure, such as a triangle, rectangle, square,hexagon, etc. so that the masters can be placed in an abuttingcontiguous relationship without any gaps therebetween. The masters (orcopies of the master) are combined in a cluster to provide a desiredpattern in a fixture, and an electrofore strip is made of the cluster.The electroformed strip is thin and flexible and with a proper supportcould itself be used directly as an embossing or compression moldingtool but in a non-continuous manner, such as the sequential typeembossing disclosed in U.S. Pat. No. 4,244,683.

Alternately, a number of electroform copies can be made from a singlemaster and these copies combined as a desired cluster in a fixture andan electroform strip made of such copies. This electroform strip alsocan be used as an embossing tool or in compression molding. In ordereconomically to provide a continuous sheet of material, it is desirableto continuously emboss the thermoplastic substrate without indexing aplurality of molds. Method and apparatus for accomplishing this isdisclosed in copending application Ser. No. 06/430,866, since issued asU.S. Pat. No. 4,478,769 on Oct. 23, 1984. That apparatus may utilize atool of the type produced by the present invention, in which the toolpattern may be at least 48" wide and have a total circumference of 115".

When producing cube-corner sheeting, the high optical quality of themaster required, permits only a relatively small master to be produced,such as 5" on a side. Accordingly, to produce an embossing tool ofsufficient size to permit embossing of wide webs from the electroformproduced from the electroform copy of the masters or the electroformcopy of the copies of the ruled master, it is necessary to duplicate andenlarge the copies until a tool of the desired size is achieved.

It therefore is an object of the present invention to produce animproved embossing tool including novel techniques for assuring accuracyof the tool master.

It is another object of the invention to produce an embossing tool largeenough to continuously emboss a wide web of material.

It is another object of this invention to produce a large scale,flexible, generally cylindrical embossing tool.

It is yet a further object of this invention to provide a novel methodto produce an improved embossing tool for embossing cube-cornersheeting.

It is another object of the invention to provide a novel method ofproducing a large scale, flexible, seamless cylindrical embossing toolemploying a plurality of individually formed masters, replicating suchmasters and through successive combination and replication of suchmasters and the resultant copies, produce such an embossing tool.

A further object of the invention is to provide a novel method ofproducing a large scale, flexible, seamless cylindrical embossing toolemploying a single master, replicating and combining such and resultantcopies to produce such embossing tool, and a method of separating suchlarge tool from a cylindrical tool mother.

Other objects and features of the invention will be pointed out in thefollowing description and claims and illustrated in the accompanyingdrawings which disclose, by way of example, the principles of theinvention and the best modes which have been contemplated for carryingthem out.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings in which similar elements are given similar referencecharacters:

FIG. 1 is a diagrammatic flow chart illustrating the various steps inproducing a cylindrical embossing tool in accordance with the presentinvention.

FIG. 1A is a partial top plan view of a completed master for producingan embossing tool for embossing cube-corner sheeting, in which themaster is prepared according to the method of the invention.

FIG. 2 is an elevational view of the master of FIG. 1A, partly insection, taken along the line 2--2 in FIG. 1A,

FIG. 3 is a fragmentary top plan view of a partially completed master.

FIG. 4 is a top plan view of a series of blank elements having differentgeometric shapes suitable for use as masters in accordance with themethod of the invention.

FIG. 5 is a top plan view of the ruled masters formed of the blanks ofFIG. 4, indicating how each of the respective types of ruled masters canbe organized into a cluster with like masters to provide contiguous andcontinuous surfaces without gaps therebetween.

FIG. 6 is a perspective representation of the manner in which triangularmasters of the type shown in FIG. 5 can be organized to permit theproduction of electroform copies of a ruled master.

FIG. 7 is a schematic representation of the technique employed to createsemi-cylindrical segments according to the present invention.

FIGS. 8 to 11 show the progressive positions and size of a shield usedduring the electroforming creation of the semi-cylindrical segmentcopies.

FIG. 12 is a representational plan view of a tank and shielddemonstrating expansion of the shield's position during electroformingof the cylindrical tool master;

FIG. 13 is a schematic representation of the arrangement of thesemi-cylindrical segment copies into a complete cylinder.

FIG. 14 is a schematic representation of the cylinder produced by thesemi-cylindrical segment copies.

FIG. 15 is a front perspective view of a suction tool used to remove acompleted cylindrical embossing tool from its mother.

FIG. 16 is a side view of the tool of FIG. 15 with the cylindricalembossing tool removed to better display the construction of such tool;and

FIG. 17 is a diagrammatic representation of a collapsed cylindrical toolprior to removal from its mother.

DESCRIPTION OF THE REFERRED EMBODIMENTS

Turning now to FIGS. 1 to 5, there are shown various aspects of a blankelement which is the basic building element for producing large scale,flexible, seamless cylindrical embossing tools according to the processof the present invention. The overall length and width of the elementwhich becomes the ruled master usually is determined by the type ofruling device used to cut the master, and the element may be on theorder of one to seven inches on a side. The outline shape of theelement, as is shown in FIG. 4, may be triangular, as at 20, square asat 23, or hexagonal as at 25. The three shapes of the elements as shownin FIG. 4, as well as others, for example, the rectangle or the octagon,or other shapes and combinations also may be employed, but preferablythe shape chosen should be a regular geometric figure which can becombined with other similar figures without permitting a gap to existbetween adjacent sides of such figures. FIG. 5 illustrates how a numberof triangular ruled masters 21 can be arranged into a cluster 22.Similarly a number of square ruled masters 27 and hexagonal masters 29can be positioned to form clusters 24 and 26 respectively.

Each element such as 20 is chosen of a thickness such that it remainsrigid during the removal of metal while undergoing generation of theruled master and during subsequent electro-forming processes. Theelement preferably is of aluminum or electro-deposited copper.

Ruling machines used in forming scribing grooves to provide a ruledmaster to make a tool for cube-corner sheeting are well known in theart. Such machines are capable of positioning the workpiece and a cutterwithin the optical tolerances necessary to scribe the grooves to opticalrequirements including proper depth, angle, spacing and a mirror finish.Typical groove spacings to form cube-corner type reflector elementsrange from 0.003 to 0.0065 inches.

As used herein, the phrases "cube-corner", or "trihedral" or"tetrahedron" are art recognized terms for retroreflective elementscomprising three mutually perpendicular faces, without reference to thesize or shape of the faces or the portion of the optical axis of thecube-corner element so formed. Stamm U.S. Pat. No. 3,712,706 disclosesvarious scientific principles and techniques for ruling a master.

The ruling device must be such that a groove uniform in angle and depthis created along its entire length, and that each successive groove alsois properly spaced and uniform. The ruling device can be of the typewhere the cutter is moved while the workpiece remains stationary or,conversely, the workpiece is moved with respect to a stationary, usuallya diamond tipped cutter. Further, the ruling device must be capable ofaccurately indexing to the second and third or more cutting positionsdifferent from the initial set of grooves.

The element 20 for the ruled master 21 of FIG. 3 is positioned upon aworkpiece support of an appropriate ruling device (schematically at "A"in FIG. 1) and the cutter thereof set to cut a first series of parallelgrooves 31, arbitrarily selected, along the axis in the direction of thearrow 32. The cutter has a V-shaped cutting edge of desired pitch anddepth.

In accordance with one aspect of the invention, before cutting of thesecond set of grooves 34, the first set of grooves 31 is filled alongthe axis 32 with a material of appropriate hardness and machinability toallow a second set of grooves 34 to be cut without interruption, as ifthe first set of grooves 31 did not exist. This allows the materialbeing removed during cutting to be pushed directly ahead of the cutterinstead of into the first set of grooves at each groove intersection,and thereby possibly distorting the intersections. The fill also servesto support the faces of the tetrahedral elements being created andprevents their distortion. Epoxy or curable polyesters can be used asthe fill materials. As noted, a second set of grooves 34 is then cutalong the axis in the direction of the arrow 35. The remaining fillmaterial (i.e., that portion not at the intersections of the secondgrooves 34 with the first grooves 31) then is removed. Fill materialthen is applied to both sets of grooves and 34 prior to the cutting of athird set of grooves. The element 20 (or tool) is then indexed to properposition to cut a third set of grooves. When the cutting of the thirdset of grooves is complete, all of the fill material is removed and theruled master 21 is ready for the next step. One suitable material is acasting polyester known as Decra-Coat manufactured by Resco. A suitableepoxy is Hardman No. 8173.

FIGS. 1A and 2 show a complete ruled master 27 having a squareconfiguration. A first set of grooves 31 was cut along the axes 32,followed by a second set 34 along the axes 35 and a third set of grooves37 along the axes 38. The intersections of the three grooves creates abase 41 for each of the tetrahedrons or cube-corner elements 40, whilethe pitch of the cutting tool determines the slope of the three mutuallyperpendicular faces 42, 43 and 44 of the cube corner elements 40. Theintersection of the planes of the faces 42, 43 and 44 is the apex 45 ofthe tetrahedron 40.

The ruling devices presently available to cut masters to the opticalaccuracy required for cube-corner retroreflectors are not capable ofcutting a single master large enough to be used directly to emboss a webof the desired width and of a length large enough to permit efficientoperation. Accordingly, the master such as 21 or 27 must be used toproduce copies which can be grouped together to form larger areas untila tool of the desired dimensions is created. Two options are possible atthis stage.

In the first approach, a number of ruled masters 21 (which may or maynot be identical) are produced and then are arranged in a cluster suchas 22, 24 or 26, and assembled in a fixture as at 49 (See FIG. 6), and athick nickel electroform solid copy is made by techniques known to thosein the electroforming arts. By the selective shielding of the solidcopies, the deposited nickel can be controlled to produce a solid copywithout interfaces and of uniform thickness throughout. This solid copythen can be used to generate additional copies needed for the next step,and the clusters 22 can be disassembled and used for otherconfigurations. The first solid copy then will be a female having beenformed from a number of the male masters 21.

A second approach employs a single master 21 which is used to generate amother copy 19 (FIG. 1) which then is replicated to generate a number ofelectro-deposited nickel copies 28 (shown at C on FIG. 1) and the copies28 of the master 21 then are arranged in a cluster 22 and assembled intoa fixture 49. A solid copy then is made from the clustered copies of theruled master 21 (steps D, E, F in FIG. 1). Two successive electroformsteps are performed so that strip 50 of male cube corner elementscorresponding exactly to the ruled master 21 is produced. As noted, thesolid copies 28 are used to generate the thin electroform copy or strip50. The thin strip 50 is then employed to form a plurality of strips 51of female cube-corner elements as shown at H, I and J of FIG. 1. Thestrips 51 are then ground on their rear surfaces to a specific thicknessto provide the desired flexibility whereby the strips 51 can be formedabout an appropriate mandrel 53 (FIG. 1, step K) for succeeding steps.For example, four strips 51, each approximately 5 inches in width and 18inches long, may be produced from the solid copies 28 and arranged abouta cylindrical mandrel 53 so as to provide a cylindrical segment copy 55(FIG. 1 step M) which is 20 inches wide and 18 inches long. Threecylindrical segment copies 55 then are employed to produce a finalembossing tool which is 20 inches wide and approximately 54 inches incircumference. Larger strips and more numerous strips 51 will be used toproduce larger tools.

FIGS. 7 to 11 (and steps J-M of FIG. 1) show the method by which thesegment copies 55 are generated. Each cylindrical segment copy 55 isabout 1/3 of the circumference of the final mother tool for generatingthe embossing tool. However, different sized segments could be made forspecific applications, such as 1/4 segments or the like. The segmentcopy 55 could be made thin and bent into its desired shape by an outersupport or it could be produced as a relatively thick member formed inits desired shape in order to retain the optical accuracy and providestrength for later operations. In the latter approach, the female strips51 are placed about mandrel 53 and both mandrel 53 and strips 51 areplaced in the electrodeposition tank 57 (see step L of FIG. 1) adjacentthe nickel anodes 61. In such position, the central portion of strips 51are closer to the anodes 61 than are the ends of strips 51. As a resultsuch ends will be plated to a lesser degree, giving the cylindricalsegment copy 55 little strength at its ends. To obviate this problem, ashield 60 (FIG. 7) of nonconductive material (e.g. plastic), is placedbetween the nickel anodes 61, and the assembled strips 51 on the mandrel53. The position and width of the shield 60 is controlled so that at thefinal stages of the electro-deposition most of the nickel ions aredirected to the strip ends to increase the thickness of the depositednickel thereat. FIGS. 8 to 11 show the successive positions of theshield 60 during plating. In FIGS. 8-11, the mandrel 53 is rotated on avertical axis for representational purposes. The strips 51 arepositioned on the mandrel 51 initially and no shield is employed asshown in FIG. 8. The anodes 61 have been omitted from FIGS. 8-11 for thesale of clarity. The anodes 61 normally would be aligned with the strips51 and exist above the plane of the paper. With such an arrangement, thegreatest nickel build up would be about the central portion of thestrips 51. As the electro-deposition progresses, it is desirable todirect more and more of the nickel ions toward the strip ends.Accordingly, the shield 60 is placed over the central portion of thestrips 51, as is shown in FIG. 9. The shield 60 is supported by twosupport rods 62 and 63, which also define the extent of the shield 60.Since the nickel ions do not pass through the shield 60, they traveltowards the ends of the strips 51 which are furthest away from theelectrodes, to build up the thickness of the electro-deposition in suchareas. FIGS. 10 and 11 show the further extent of the shield 60. Adiagrammatic representation of the shield 60 on successive time periods2, 3 and 4 is illustrated in plan view in FIG. 12. During period 1, thestrip 51 is fully exposed (no shield).

When completed, the segment copies 55 (FIG. 1) with their precisionpatterns on the inside, and each comprising 1/3 of the circumference ofa final cylinder, are placed within fixtures (not shown) for support todefine a segment cylinder 65 (FIG. 14). Using the assembled segmentcylinder 65 as the negative electrode with an accurately positionednickel anode in the center of the cylinder 65, the segment cylinder 65will be plated on its inside diameter to generate a thin flexible butsolid seamless master cylinder 70 having flash or fins which can beground off so no stress risers are transferred to the next part. Thiscylinder then could be used as a model to produce similar cylinderswithout repeating all of the previous steps (steps A-N in FIG. 1). Thesegment disassembled into the segment copies 55, leaving the tool mastercylinder 70.

The master cylinder 70 now consists of female cubes which are situatedon the outside diameter. This cylinder 70 is identical in configurationto that which is required as an embossing tool, however, tools producedby this method (using several segments 55 joined together as a mandrel)have a number of disadvantages. They require an intricate assembly anddisassembly of the segment fixture which requires precision alignment.Also of concern is the interface between the thin segments 55 whichcontain extremely small fissures. Although this discontinuity is almostnon-detectable, it causes a difference in the crystalline structure ofthe metal deposited over it. This change results in stress-risers whichbecome lineal imperfections causing early fatigue failures in parts thatwill be flexed during embossing.

These problems of assembly and metallurgy are avoided by the presentinvention. The tool master cylinder 70 will have surface imperfectionssuch as flash, due to the fissures in the mother fixture, removed bygrinding. Once this flash is removed, subsequent copies made from suchpart will not contain stress risers or alterations in the metallurgicalstructure, although this cylinder 70, when used as a mandrel does havethese imperfections.

With proper fixturing (not shown), the tool master cylinder 70 then isrotated during subsequent electroforming, with nickel anodes adjacentits outer surface to form a thick electroform mother cylinder 75, on theorder of 0.050" to 0.100", as compared to the tool master cylinder 70which is of a thickness of only 0.010" to 0.030".

The thick mother cylinder 75 then becomes the negative of a cylindricalembossing tool 80. Both mother cylinder 75 and the cylindrical embossingtool 80 formed on the inner surface thereof are continuous and seamless.

The present invention utilizes a novel method to separate the seamlessembossing tool 80 from the mother cylinder 75, without damage to either.Normal "sweating" techniques (expanding one cylinder and contracting theother by temperature differential), cannot be employed because of thedepth of the male cubes plated into the female counterparts. To provideseparation, the inner cylinder is fixtured with a vacuum apparatus 90(FIGS. 15-17). The vacuum apparatus 90 consists of a tube 91 to which isaffixed several hollow suction cups 92. Independently controlled hoses93 and 94 are affixed one to each cup 92 (see FIG. 16) to create avacuum. Each cup 92 is secured to the tube 91 by threaded rods 95 andnuts 96. Mechanically raising cup 92 by rotating one nut 96 at one endof one cup, causes the cup to lift the underlying cylindrical tool 80from the mother 75. This then lifts a portion of the thin and flexibleinner tool cylinder 80 away from the rigid outer cylinder 75. Normally,the negative effect of a vacuum in this direction would be cancelled bythe intimate contact of the two parts and not allow separation. In thiscase, the breaking force is initially applied mechanically at the veryedges of the cylinders which allows air to enter between the twocylinders. Once the edges are separated, the additional cup or cups 92that run along the line of separation are mechanically adjusted tocontinue to apply the vertical vacuum force along a wider path,stripping the inner tool part 80 along this line (FIG. 16). Once thelength of the cylinder 80 has been separated along this line, the endsof the inner tool cylinder 80 can be held up mechanically or manuallyand the vacuum apparatus 90 removed. The thickness of the tool 80 (about0.010" to 0.030") permits it to flex without damage to the cube cornerelements.

The inner cylinder 80 then is totally collapsed, (FIG. 17), eithermanually or by mechanical means. At this point, a thin protective filmsuch as Mylar is positioned between the two cylinders 75 and 80 toinsure removal without digging either surface.

The inner tool cylinder 80 then is pulled clear from the outer cylinder75 and recovers its shape.

Once removed, the heavy mother cylinder 75 can continue to be used toproduce similar embossing tools 80 at a rate of 12 to 48 hours per copy,depending on the plating rate used.

The process disclosed herein can be varied along the various steps if asmaller embossing tool is required or extended if a larger tool isdesired. Although the tool 80 is described as a cylinder during itsproduction, because of its ability to flex, it may be employed in otherforms. For example, it may be used as a belt having two long sides withshort curved ends where it passes over drive rollers (step T of FIG. 1).

It will be understood that while the present invention describes themaking of a cylindrical tool for embossing cube corner sheeting, theprinciples of the invention are applicable to any type of tool in whichaccuracy of the embossed surfaces are desired for a specific reason, andthe noted technique for separation of the cylindrical tool from itsmother is applicable to any cylindrical parts formed with an interferingpattern that prevents "sweating" or other simple separation of twoseamless cylinders.

While there have been shown and described and pointed out thefundamental novel features of the invention as applied to the preferredembodiments, it will be understood that various omissions andsubstitutions and changes of the form and details of the devicesillustrated and in their operation may be made by those skilled in theart, without departing from the spirit of the invention.

What is claimed is:
 1. A thin seamless generally cylindrical flexibleelectroformed embossing tool, having on its outer surface an opticallyprecise continuous pattern having sharp angles and flatness of faces incertain detail formed thereon by electroforming, for continuousembossing of a web of material with such optically precise pattern,which pattern includes multiples of smaller contiguously arrangedoptically precise patterns each pattern having its longest dimension ofless than one inch.
 2. The embossing tool set forth in claim 1 whereinthe precise pattern comprises an array of cube-corner type elements. 3.A thin seamless generally cylindrical flexible electroformed embossingtool, having on its outer surface more than one optically precisecontinuous pattern, each said pattern having sharp angles and flatnessof faces in certain detail formed thereon by electroforming, forcontinuous embossing of a web of material with such optically precisepatterns each said pattern including multiples of smaller contiguouslyarranged optically precise patterns, each said smaller pattern havingits longest dimension of less than one inch.
 4. The embossing tool setforth in claim 3, wherein said tool is between 0.010" to 0.030" inthickness.
 5. The embossing tool set forth in claim 3, wherein eachprecision pattern is defined by a rectangular perimeter.
 6. Theembossing tool set forth in claim 5, wherein the length of the edge ofsaid rectangular pattern is about 0.16 inch.
 7. The embossing tool setforth in claim 5, wherein an edge of each adjacent pattern is positionedto have a different angular position relative to an edge of a contiguouspattern.
 8. The embossing tool set forth in claim 3 wherein each of saidmore than one optically precise patterns comprises an array ofcube-corner type elements.
 9. The embossing tool set froth in claim 8,wherein the base of each of said cube corner elements comprises anequilateral triangle.
 10. The embossing tool set froth in claim 8wherein said cube-corner elements are defined by series of firstparallel grooves located between 0.006" and 0.012" to adjacent grooves,and intersecting second and third parallel grooves at 120° measurement.11. The embossing tool set forth in claim 10, wherein the base of eachof said cube-corner elements comprises an isosceles triangle.